Model 4069E User’s Manual Publication #: 107606-001 Rev. 1 Feb. 2009 Another quality product from: 7128 Shady Oak Road, Eden Prairie, MN 55344 Phone: (952) 949-9009 Fax: (952) 949-9559 E-mail: info@researchinc.com www.researchinc.
Dear Valued Customer: Thank you for purchasing a Model 4069E ExtrudeIR® infrared heater. We believe it is the finest heating system of its type and are confident you will think so also. This instruction manual has been carefully prepared to ensure you will be able to easily install and operate the Model 4069E curing system and to fully realize all its inherent capabilities. We invite your comments as well as any issues you may have regarding this manual or the Model 4069E.
Model 4069E ExtrudeIRTM USER Manual Section Contents page INTRODUCTION General Description Standard Features Optional Features SAFETY 1 1 2 3 SPECIFICATIONS Specifications Dimensions 4 5 INSTALLATION Wiring Connections Wire Ratings Wire Sizes Electrical Inputs Power Wiring Connections Control Connections Remote Interlock Switch Remote Fast Stop Water Connections Air Connections 10 10 10 10 10 12 12 12 12 12 OPERATING INSTRUCTIONS Controls and Indicators Main Disconnect System On /Off Switch Indic
Model 4069E ExtrudeIRTM USER Manual Contents DIMENSIONS AND SPECIFICATIONS Controls Heater 20 22
Model 4069E ExtrudeIRTM Instruction Manual Introduction Introduction General Description The Model 4069E ExtrudeIR curing System uses high intensity infrared lamps and polished aluminum reflectors to deliver heat precisely where it is needed for many curing and drying applications on extrusion lines. It can be used effectively to provide a surface cure to rubber extrusions, dry adhesives and coatings on rubber or metal, and provide in process curing between layers of multi layer cable.
Model 4069E ExtrudeIRTM Instruction Manual Standard Features Introduction Heater Positioning – The chamber is mounted to actuators at each end allowing for variations on product elevation. Each actuator can operate independently allowing for up to 15° off chamber tilt. This can be useful when product sagging is occurring. Water Cooling – Each reflector is designed with an internal coolant passageway to allow coolant to flow through its entire length during operation.
Model 4069E ExtrudeIRTM Instruction Manual Booster Pump – An optional booster pump is available when plant water pressure is too low to provide adequate flow rate for proper cooling of the chamber. Pump will raise the water pressure up-to 50 PSI General Introduction Electrical Safety The Model 4069E heater is designed for safe operation. Nevertheless, installation, maintenance, and operation of the heater can be dangerous for a careless operator or maintenance person.
Model 4069E ExtrudeIRTM Instruction Manual Introduction CAUTION! Observe all applicable local and national electrical codes and ensure that a safe electrical ground system is installed before attempting to operate the heater. Refer to the Section 5 for proper installation procedures. WARNING! ALWAYS disconnect the external power lines prior to servicing the heater. ALWAYS disconnect the power lines AND any optional interlock circuits before installing or changing lamps.
Model 4069E ExtrudeIRTM Instruction Manual Introduction 4069E-12R-25L-30kW-480V 4069E-12R-38L-46kW-480V 4069E-12R-10L-DUAL18kW-480V 4069E-18R-10L-18kW-480V 4069E-18R-16L-29kW-480V 4069E-18R-25L-45kW-480V 4069E-18R-38L-68kW-480V 4069E-18R-10L-DUAL36kW-480V 2500 3800 1000 1000 1600 2500 3800 1000 10 240 19.2 1.8 (6.9) 16 480 30.0 480 45.6 240 24 2.8 (10.6)** 4.2 (15.9)** 31 63 2.4 (9) 20 1.7 (6.5) 15 240 28.8 2.7 (10.2) 29 240 18.0 480 45.0 480 68.4 240 36 4.2 (15.7)** 3.1 (11.
Model 4069E ExtrudeIRTM Instruction Manual Research, Inc.
Model 4069E ExtrudeIRTM Instruction Manual Operating Instructions DIMENSIONS A 32.63 D DIA C B 44.00 MODEL NUMBER 4069P-12R-10L 4069P-12R-16L 4069P-12R-25L 4069P-12R-38L 4069P-18R-10L 4069P-18R-16L 4069P-18R-25L 4069P-18R-38L 4069P-12R-10L-DUAL 4069P-18R-10L-DUAL Research, Inc. A 16.13 (410) 21.75 (552) 30.75 (781) 43.75 (1111) 16.13 (410) 21.75 (552) 30.75 (781) 43.75 (1111) 38.39 (975) 38.39 (975) B MIN MAX 36.75 44.75 (933) (1137) 36.75 44.75 (933) (1137) 36.75 44.75 (933) (1137) 36.75 44.
Model 4069E ExtrudeIRTM Instruction Manual Operating Instructions Single Chamber 2 Inch Diameter Profile Model 4069E-12R-10L 4069E-12R-16L 4069E-12R-25L 4069E-12R-38L Power Generated 12kW 19.2kW 30kW 45.6kW Voltage 240 volt 3 phase 240 volt 3 phase 480 volt 3 phase 480 volt 3 phase Max Current 29 amp 46 amp 36 amp 55 amp Breaker size 50 amp 60 amp 50 amp 70 amp Lamp Type 103390-003 103390-005 103390-007 103390-010 Water Flow Requirement 1.2 gpm (4.5 lpm) 6.8 gpm (12.
Model 4069E ExtrudeIRTM Instruction Manual Operating Instructions Installation This section describes how to wire the Model 4069E power control system. The features and options mentioned here are identified in the model number found inside the enclosure. WARNING! Hazardous voltages are present at the main disconnect switch and load terminals. Always remove AC line voltage from the system before making contact with internal assemblies, line or load wiring, or fuses.
Model 4069E ExtrudeIRTM Instruction Manual Operating Instructions CONNECT POWER THIS SIDE IF POSSIBLE Figure 1. Research, Inc.
Model 4069E ExtrudeIRTM Instruction Manual Operating Instructions Power Wiring Connections Line Connections Referring to the wiring specification in Table 3-1, connect the external power lines to the top of the disconnect switch. Load Connections The model 4069E control system has 2 (3-pole) load fuseblocks for distributing the Three-phase power to your process. For the 120 Amp systems, do not exceed more than 60 amps – 3 phase per fuseblock.
Model 4069E ExtrudeIRTM Instruction Manual Operating Instructions CONTROL CONNECTIONS Remote Interlock Switch This feature provides for remote process interlock shutdown of the heater power. This is accomplished by opening the heater power controller contactor. With the interlock open, the heater cannot be turned on from the control system front panel. The switch contacts must be open during the heater off condition. If this feature is desired, connect using the following procedure: 1.
Model 4069E ExtrudeIRTM Instruction Manual Operating Instructions Operating Instructions Figures 4 & 5 shows the location of the controls and indicators. CONTROLS AND INDICATORS Main Disconnect Switch The main disconnect switch turn on and off the power control system. Note the following: Before turning on the disconnect switch, check the following: 1. The load is wired and ready for power to be applied to it. 2. All safety precautions are observed.
Model 4069E ExtrudeIRTM Instruction Manual Actuator Control Operating Instructions The black/white buttons on the control console control movement of the actuators that provide elevation adjustments to the chamber. • The left black/white controls the left actuator. • E-stop (Fast Stop) The right black/white controls the right actuator. Activation of the E-stop will disable the chamber contactor which cuts power to the lamps, cooling fan and water and air solenoids.
Model 4069E ExtrudeIRTM Instruction Manual Operating Instructions Actuator Control (Left) Watlow Controller Actuator Control (Right) On/Off Switch Figure 5. Research, Inc.
Model 4069E ExtrudeIRTM Instruction Manual Dimensions and Specifications Maintenance and Trouble Shooting ROUTINE MAINTENANCE The following bi-monthly routine maintenance is suggested: 1. Remove power connection to the system. Lock out power if possible. Carefully vacuum any dust or dirt collecting within the enclosure. Use caution to not disturb the wiring. Service more often in dust locations. 2. Clean the outside of the enclosure with glass cleaner and a soft cotton cloth as necessary.
Model 4069E ExtrudeIRTM Instruction Manual Dimensions and Specifications Figure 6. 10. Cut wire to a length allowing for a service loop. 11. Strip back the insulation on the end of the lamp leads approximately 1-1/2 inches (38 mm). 12. Insert the bare wire of each insulated lamp lead into the ceramic terminal block position that previously held the old lamp. Push each lead wire into the terminal block far enough so, that when tightened, the setscrew will hold the lead securely. 13.
Model 4069E ExtrudeIRTM Instruction Manual Dimensions and Specifications Note: Remove all power from the heater BEFORE attempting to install/replace the lamps. Always use clean cotton or latex gloves when handling the split quartz liner so as not to deposit any oils or grease from your hands onto the surface of the split quartz liner. 1. 2. Open the Model 4069 Heater to allow access to each heater half for split quartz liner installation.
Model 4069E ExtrudeIRTM Instruction Manual Dimensions and Specifications Figure 9 5. 6. 7. 8. CLEANING THE REFLECTORS If cleaning the liner, use a non-abrasive glass cleaner (i.e. household ammonia and water or isopropyl alcohol) and a clean, dry, lint-free cloth. After cleaning, do not touch the outside surface of the liner unless wearing cotton gloves. Reinsert the edges of the liner into the grooves of the quartz-liner bracket. Reinstall the other bracket and secure with the two bracket screws.
Model 4069E ExtrudeIRTM Instruction Manual Dimensions and Specifications The reflectors can be removed from the Model 4069 Heater to make cleaning and maintenance easier. The following procedure should be used to remove the Model 4069 reflectors: Note: Remove all power from the heater BEFORE attempting to install/replace the heater reflectors. 1. Drain all cooling fluid from the heater and blow out the heater cooling lines with compressed air. 2. Remove the heater-cover screws and heater cover.
Model 4069E ExtrudeIRTM Instruction Manual Dimensions and Specifications Figure 11 Research, Inc.
Model 4069E ExtrudeIRTM Instruction Manual TROUBLESHOOTING Symptom Heater Contactor will not energize. Dimensions and Specifications Action 1. Verify line voltage is applied to the main disconnect switch. 2. Verify remote heater open, remote process interlocks or water flow switches (if used) are closed. 3. If not using remote heater enable, heater open interlocks or water flow switches, verify the 2 pin jumpers are installed between TB 100 pins 2 to 3, 10 to 11 and 14 to 15. 4.
Model 4069E ExtrudeIRTM Instruction Manual Dimensions and Specifications Symptom No output to load, heaters or lamps. Setpoint switch is in REMOTE. Operation O.K. with Setpoint switch in LOCAL (if not see above). Action 1. Verify the polarity of the remote input. TB 100 pin 16 is positive, and 17 is negative. Full voltage cannot be obtained. 1. Verify the load, lamps, or heaters are not drawing current at full capacity of the system.
Model 4069E ExtrudeIRTM Instruction Manual Research, Inc.
Model 4069E ExtrudeIRTM Instruction Manual Dimensions and Specifications Accessories, Spare, and Replacement Parts – Controls Model Description Control Cabinet: 096191-006 107556-009 086445-016 090744-020 099395-001 099396-001 107549-001 099556-003 099556-010 080821-001 055899-015 107321-001 066798-004 055300-289 Contactor- 3 phase, 100 amp, 24 VDC coil Fuse-Cubefuse, 100 amp Fuse-Time Delay, “CC”, 6 amp, 600 VAC Fuse-Current Lim “CC” 1.
Model 4069E ExtrudeIRTM Instruction Manual Dimensions and Specifications Accessories, Spare, and Replacement Parts – Heater Model Description Replacement Lamp For: 103390-003 103390-004 103390-005 103390-012 103390-007 103390-010 12kW or 18kW maximum-power rated heater (10 inch length, 1000-watts) 24kW or 36kW maximum-power rated heater (10 inch length, 2000-watts) 19kW or 29kW maximum-power rated heater (16 inch length, 1600-watts) 56KW maximum power rated heater (16 inch length, 3600-watts) 30kW or 4
